Expanded metal



Jan. 19, 1965 Q Q @QQQ %%Q Q 33 @Q WV WY United States Patent 3,165,310 7 EYQANDED l t ETAL V 7 Wave B. Agler, Hammond, Ind, asslgnor to Pentron Electronics Corporation, Chicago, E51,, a corporation of Illinois Filed Aug. 3, 1962, Ser. No. 214,745 8 Claims. (Cl. 296.2)

This invention relates, generally, to expanded metal and I p 3,165,8lll Patented Jan. 1%, 19 65 ice through which attachment means such as bolts, screws and the like can be inserted.

In accordance with conventional practice the intermediate expanded portion 12 is formed by diamondshaped openings 14 each of which is formed by strands 15 and 16 which are slit from the imperforate metal sheet and then drawn to form the diamond shape. The long diagonal of the openings 14 is indicated. at 1'7 while the short diagonal is indicated at 18. It will be understood that the relative lengths of the diagonals 17 and 13 will vary depending upon the lengths of the strands 15 and 16 and their configuration. The bond area between the strands complete the expanded metal sheet; to form transverse rows of openings in an imperforate metal sheet of indefinite length and of definite width in predetermined spaced relation therealong; to cause the formation'of each row of openings in response to the movement of a previously formed row to a predetermined position; to initiate a slitting and drawing operation for the purpose of forming the first row of diamond shaped openings on move ment of a row of transverse openings into a position where one-half of the strands defining this first row of diamond shaped openings can be drawn ther'einto; and to crop the leading end of the metal sheet to be expanded in predetermined spaced relation to each transverse row of openings in order to provide an imperforate leading end section. j

In the drawings: FIG. 1 is a top plan view of an expanded having'imperforate leadingand trailing end portions, the sheetbeing broken'l'ongitudinally and transversely in order to illustrate the construction at a relatively large scale. FlG,,2 is a top plan view ofa portion ofthe imperforate metal sheet provided with a transversely extending row of elongated openings with openings at the ends of the row'of halfthe area of the adjacent elongated openings which permit the strands tormingthe first row of diamond shaped openings to be drawn thereinto.

' FIG. 3 illustrates, diagrammatically, apparatus that can metal sheet sheet with the elongated openings 20 is positioned in a] conventional sheet metal expanding machine with these 15 and 16 is indicated M19.-

With a view to facilitatingthe formation of the first row of diamond shaped openings 14 the imperforate metal sheet is provided with a transverse row of elongatw openings each of which is indicated at 2%) in FIG. 2 of thedrawings. The row of elongated openings 26 is located at a distance, indicated at 21, FIG. i, from the leading edge of the end portion 11 which depends upon the desired width of the imperforate leading end portion 111. It will be understood that the width, as indicated at 21, can be 'varied as may be desired. Preferably the elongated openings 2% have semi-circular end portions 22ZZ in order to avoid sharp corners where stresses might be concentrated leading to fracture of the material. As shown'in FIG. 2 the length of each of the elongated openings 20 is indicated at 23 and this length is about the same as the length of the long diagonal as indicated at 17 in FIG. 1.

The Width of each elongated opening 29, as indicated at diamond shaped openings 14 throughout the entire area of the intermediate expanded portion 12. The unexpanded openings slightly beyond the blade block such that the first strands, for example the strands 15, are sheare'dand drawn by the die on its first down stroke into the respective openings 26. This is accompanied by swinging move- FIG. 4 showsQdiagrammatically, a portion of the. con- 'trol system that can be used for controlling the operation metal sheet 13 can be of steel, aluminum, copper, etc.,

depending upon the ultimate use to which the expanded metal sheet 10 is to be put. It is provided at itsleading end portion with'an' imperforate end portion 11 that is joined at one end to an intermediate expanded portion 12 which: terminates in an imperforate trailing end portion 13. It is desirable to have the imperforate end: portions 11 and 1 3 inorder to facilitate use of the expanded metal V are provided end openings 25-25 which have the same width: as the elongated openings; 20 but have a length sheet 10 for purposes such as a shelf in a refrigerator or like application. The provision of thefimperforate end portions 11 and 13 facilitates the mounting of the sheet 19 as'may'bedesired and servesas end border portions -ment of the imperforate leading end portion 11 and the strands 15 through an angle of which movement' is conventional in sucha machine. The next strands 16 are likewise sheared and drawn onthe next stroke of the die which in the meantime. has been shiftedlaterallyand they are swung into the plane of the end portion 11. operation continues until the desired number of diamond shaped'openings 14 has been formed with the desired width or" the trailin end portion 13 which, at'the termination of the slitting and drawing operations, is;at right angles to the plane of the end portion 11 andthe strands.) 15, 15 etc. After removal from the machine, the trailing;

end portion 13 is swung into the-planeof-the remainder I of the expanded metal sheet 14). At the endof the row of'elongatedopenings 20 there indicated at 26 which is'equal to one-half the length cated at 23 for the-elongated openings 29. This construc- 1 tion permits the drawing of the free. half strand portions 27 27, BIG. 1, into theend openings 2525 where they .1 are symmetrical with the corresponding portions'ofthe The strand 15 or where they may be turned to form a reverse bend as may be desired.

The bond areas 28 which constitute integral continuations of the portions 29 of the imperforate metal sheet between the semi-circular end portions 2222 is some What larger in area than the bond area 19. The reason for this is that the bond areas 23 are formed, in part, by the portions 29 and the slitting operation is performed only on one side. The elongated openings 20 and the end openings 2525 of generally U-shape can be formed by any suitable means. They can be formed by drilling operation. Other machine tool operations can be used. Preferably provision is made for punching them by a single operation of a punching die. However, other means can be used for forming the openings 20 and 2525 as may be desired, depending upon the kind and character of the metal forming the sheet to be made into the expanded metal construction.

FIGS. 3 and 4 illustrate, somewhat diagrammatically, how the expanded metal sheets 19, shown in detail in FIG. 1, can be manufactured. Here it will be observed that the expanded metal sheet is shown at a reduced scale and not in the detail that it appears in FIG. 1. The width 32 of the intermediate expanded portion 12 can be as great as desired, depending upon the use to which the final product is to be put. Similarly, the width 33 of the *lmperforate trailing end portion 13 can be as desired. The

width 33 may be same as the width 21 of the imperforate leading end portion 11 or may be ditferent, as shown.

In order to manufacture the expanded metal sheets 10, one by one, a metal sheet 34 of indefinite length and definite Width is provided. Ordinarily, the metal sheet 34 -is in the form of a roll or coil of sheet metal which is mounted on a suitable mandrel and unrolled in the direction indicated by the arrow 35 for movement toward a punch that is indicated, generally, at 36. It will be understood that the punch 36 is provided with suitable simultaneously operable dies which are arranged to form the elongated openings 20 and the end openings 2525 as the result of a single operation. The punch 36 is of conventional construction and is arranged to be driven by a punch motor drive and control that is indicated, generally, at 37.

The row of elongated openings 26' and end openings 2525 being made by the punch 36 is indicated at 38. A previously formed row is indicated at 39 and a still previously formed row is indicated at 40. Provision is made "for detaching or cropping the previously completed expanded metal sheet 10 from the metal sheet 34 along the line indicated at 41. It will be understood that the line 41 is spaced from the transverse row 49 of openings 20 and 25-25 at a distance which is determined by the desired width 21 of the irnperforate leading end portion 11.

It will be observed that the leading end of the metal sheet 34 is moved into an expander and cropper that is indicated, generally, at 42. This device is of conventional construction and an expander and cropper motor drive and control,shown generally at 43, is provided for driving the expander and cropper 42 for the purpose of slitting and drawing the strands 15, 16 and 27 to form the diamond shaped openings 14 shown in FIG. 1. As pointed out .hereinbefore the expander and cropper 42 is operated in such manner with reference to the openings 20 and 2525 as to slit the strands 15 and 27 and to draw them into the respective opening and 27 to form with the strands 16 a symmetrical configuration for the diamond shaped openings 14.

FIG. 4 shows diagrammatically a portion'ofthe control system that can be employed for controlling the operation of the punch motor drive and control 37 and it, light rays 47 therefrom impinge upon a photoelectric.

cell 48. If the row 39 is the immediately preceding row of openings 20 and 25 that has been formed, then the distance between this row and the row 38 to be formed by the punch 36 is a predetermined value and depends upon the desired width 32 of the intermediate expanded portion 12 of the expanded metal sheet 10. It will be understood that, when the light rays 47 impinge on the photoelectric cell 48, the circuit arrangement is such that the punch motor drive and control 37 is operated to cause the punch 3d to form the row 38 of openings 26 and 25--25.

In a similar manner the expander and cropper 42 can be controlled. For this purpose a light source 49 is provided and when its light rays 50 are projected through one of the openings 20 in the row 4!) of openings 20 and 2525 at a location where the first row of diamond shaped openings 14 is tov be formed, these rays impinge on a photoelectric cell 51 which, in turn, initiates the op- ,the'expander and cropper motor drive and control 43. .Here it will be observed that the light source 46, such as eration of the expander and cropper motor drive and control 43 to start the operation of the expander and cropper 42 for the purpose of forming the diamond shaped openings 14 in a number and configuration, depending upon the use to which the expanded metal sheet ultimately is to be put. At the same time a cropping shear blade 52 is operated to crop the metal sheet along the line $1 for the purpose of detaching the completely formed expanded metal sheet 10.

Once the apparatus shown in FIGS. 3 and 4 is started in operation, the manufacture of the expanded metal sheets 1%] in the configuration shown in FIG. 1 continues until all of the metal sheet 34 has been converted into expanded metal sheets.

What is claimed as new is:

1. In the method of making an expanded metal sheet from an imperforate metal sheet, the steps which comprise:

(a) forming a row of openings in the sheet,

(b) slitting the sheet along one side of each opening and forming a strand adjacent thereto,

(c) drawing each strand into the respective opening and forming one-half of a generally diamond shaped opening, and

(d) continuing the slitting and drawing to form complete generally diamond shaped openings.

2. The invention, as set forth in claim 1, wherein the openings in the row are elongated and of a length about the same as the length of the diagonal of the respective diamond shaped opening parallel thereto.

3. The invention, as set forth in claim 1, wherein at each end of the row of openings an opening is formed of generally U-shape the area of which is one-half that of the adjacent opening in the row.

4. The invention, as set forth in claim 1, wherein each row of openings is formed in response to the appearance of a previously formed row of openings at a predetermined position.

5. Thexinvention, as setforth in claim 1, wherein the slitting and drawing operations are initiated in response to the appearance of a row'of openings at a predetermined position.

6. Apparatus for manufacturing expanded metal sheets from a metal sheet of indefinite length and definite width comprising, in combination:

(a) means for forming rows of openings in the metal sheet in predetermined spaced locations therealong,

(b) means for cropping the metal sheet in predetermined spaced relation to each row of openings to provide an imperforate leading end section for the sheet, and i (c) means forslitting and drawing the metal sheet into rows of diamond shaped'openings with the strands defining one-half of the first-row of diamond shaped openings being drawn into the respective opening of each row of openings.

7. The invention, as set forth in claim 6, wherein means control the forming means to make each row of openings in response to the appearance of a previously formed row of openings at a predetermined position along the path of movement of the metal sheet to the slitting and drawing means.

8. The invention, as set forth in claim 6, wherein means control the slitting and drawing means to initiate the formation of the rows of diamond shaped openings in response to the appearance of a row of openings in a position to have the strands defining one half of the first row of diamond shaped openings drawn into the same.

References Cited in the file of this patent UNITED STATES PATENTS 1,448,109 Dean Mar. 13, 1923 2,018,085 Otte Oct. 22, 1935 2,633,630 Woods et a1. Apr. 7, 1953 2,861,326 Bergstrom Nov. 25, 1958 2,871,551 Harris Feb. 3, 1959 2,944,329 MacKay July 12, 1960 OTHER REFERENCES Penmetal, Penn Metal (30., R0. Box 1468, Parkersburg, W. Va., 1962, p. 12. 

1. IN THE METHOD OF MAKING AN EXPANDED METAL SHEET FROM A IMPERFORATE METAL SHEET, THE STEPS WHICH COMPRISE: (A) FORMING A ROW OF OPENINGS IN THE SHEET, (B) SLITTING THE SHEET ALONG ONE SIDE OF EACH OPENING AND FORMING A STRAND ADJACENT THERETO, (C) DRAWING EACH STRAND INTO THE RESPECTIVE OPENING AND FORMING ONE-HALF OF A GENERALLY DIAMOND SHAPED OPENING, AND (D) CONTINUING THE SLITTING AND DRAWING TO FORM COMPLETE GENERALLY DIAMOND SHAPED OPENINGS. 